Pre-molded window, door and floor frame incorporated into a building wall construction

ABSTRACT

A plurality of composite building components for use with an erectable wall associated with a building enclosure and for establishing an environmentally resistant barrier proximate a floor supporting bond and/or a window/doorway defining enclosure. Each of the components further includes an elongated body having a specified cross-sectional dimension which is constructed of a composite including a plasticized material with additional binder element. The elongated bodies are secured in end-to-end connecting fashion, both upon the perimeter-defining foundation as well as at locations corresponding to a window or doorway defined within the erectable wall. A plurality of floor joists are supported in spaced apart and extending fashion between spaced apart and parallel extending components comprising the perimeter-defining foundation. The foundation defining components further include a brick ledge support.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to molded construction membersand, more particularly, discloses a composite building component in theform of a pre-molded and elongated bond member for use in structuralwall applications associated with window, door and brick ledge supportsof an enclosure. The structural bond member of the present inventionfurther incorporates various modified “L” and “T” cross-sectional shapedstructures which are manufactured from a plastic/sawdust composite orheavy-duty fiberglass construction in order to provide the combinedfeatures of water and termite infestation resistance.

2. Description of the Prior Art

The prior art is well documented with examples of floor and wallconstruction systems. The objective in each instance is to simplify thetime and effort necessary to construct a building enclosure, as well asto incorporate improved materials and techniques which reflect in thequality and durability of the structure so erected.

U.S. Pat. No. 4,389,831, issued to Baumann, teaches a simplifiedconstruction system in which a box-like building is constructed one roomat a time and by which concrete slabs are used for building the walls,floor and ceiling. These are poured in a horizontal position, and arestacked vertically with bond-breaking layers between them to allowseparation.

A plastic sheet is applied as a bond-breaking layer to the upper surfaceof the foundation and, after the foundation and stub wall are partiallycured, a ceiling slab is poured with wedge-shaped edges clearing stubwalls by approximately one inch. Tiltable wall slabs are then poured ontop of the ceiling slab, each connected by hinges to its own stub wall.An accelerated lightweight and low-slump concrete is normally used,which makes possible a rapid, nearly continuous pouring sequence.

U.S. Pat. No. 3,867,802, issued to Murphy, teaches a floor supportassembly for building structures which includes a beam having a ledge, afloor joist and a locking clip for connecting the joist to the beam. Anelongated bottom wall portion of the joist terminates at an end, and apair of the walls project along the length of the bottom wall and at anangle thereto so as to form a member having a generally V-shaped crosssection. Each of opposing side walls include a ledge extendingtherealong, the ledges being coplanar and adapted to be received withinrespective grooves in a floor panel to support the panel therealong. Thejoist is supported at its end by the ledge of the beam and is connectedto the beam by the clip. Of note, the beam includes a flange portion forconnection to a similar beam to form a hollow beam section which notonly serves as a support for associated floor joists, but also serves asa heating and/or cooling duct.

U.S. Pat. No. 5,473,849, issued to Jones, Jr., teaches a building walland method of constructing the same and which provides hollow coredwalls, beams, girders, joists and the like, these typically beingconstructed of a manufactured and exterior-grade fiberglass reinforcedcement board, and within which is poured a flowable fibrous, foam-cementmix. In relevant part, the fiber-foam cement core supplies structuralstrength, insulating properties and monolithic bonding of allcomponents. An inner, cement board creates the interior side of the walland an outer cement board is used as a permanent form creating one sideof the building wall.

U.S. Pat. No. 6,550,215, issued to Pulte et al., teaches a casting toolfor forming precast concrete walls. A base is disposed generally in ahorizontal plane and has an upper surface. A pair of opposing sidewallsare disposed proximate the upper surface. Each of the sidewalls has afirst position in which the sidewall is located substantially in avertical plane.

First and second opposing bulkheads are disposed proximate the uppersurface, each having a respective first position in which the bulkheadis located substantially in a vertical plane. The bulkheads are furtherarranged to abut the pair of opposing sidewalls so that the innersurfaces of the sidewalls, the bulkheads, and the upper surface of thebase define a form for receiving concrete to make the precast concretewall section. The first bulkhead is configured for movement so as tovary a first dimension of the form, and thus the dimension of theconcrete wall section.

Finally, U.S. Pat. No. 4,454,695, issued to Person, teaches a compositefloor system including a plurality of joists, each having a top and abottom chord and a web in the space between the chords. The top chordincludes a pair of angle bars, each having a vertical leg of differingheights and a horizontal leg. The top of the web extends between thevertical legs of the chord to a point between or level with the top ofthe larger vertical leg of the angle bars. Decking is supported by thehorizontal legs of the top chord of adjacent joists and a concrete slabpoured on the decking and between the vertical legs of the top chord toprovide bonding between the concrete slab, top chord and web.

SUMMARY OF THE PRESENT INVENTION

The present invention relates generally to molded construction membersand, more particularly, discloses a pre-molded and elongated compositebuilding component, or bond, for use in structural wall applicationsassociated with window, door and brick ledge supports of an enclosure.The structural bond member of the present invention further incorporatesvarious modified “L” and “T” cross-sectional shaped structures which aremanufactured from a plastic/sawdust composite or heavy-duty fiberglassconstruction.

In a first application, the elongated components are arranged in anend-to-end connection fashion upon a perimeter-defining foundationassociated with the building structure. Typically, the bond componentsare constructed, such as within a press application, of a compositematerial including a plasticized resin mixed with a sawdust and binder.Alternatively, the components may be constructed with fiberglass orother suitable material which exhibits the necessary properties ofstrength, durability, and environmental insulation.

The elongated components exhibit any desired cross-sectionalconfiguration, among those including an “L” shaped, “T” shaped or “U”shaped design. A reinforcing insert may be embedded in axially extendingfashion within the elongated component, such as during its press orformation stage, and may include a metal, wood, heavy-duty nylon orother suitable material which provides the necessary degree ofreinforcement to the component. The insert may also be configured toreplicate the overall “L”, “T” or “U” shaped cross section of thematerial in order to maximize the overall rigidity of the componentalong its axial direction.

In one preferred application, the elongated components are assembled inend-to-end engagement upon the building foundation, this beingaccomplished either by integrally forming the components with thefoundation or, alternatively, by securing the same with glue, fastenersand the like. The foundation “bond” layer thus created exhibits desiredwaterproof and infestation-resistant properties, and may also beconfigured along its cross-sectional extending dimension to provide bothan inner support ledge for a plurality of inner extending floor joists,as well as an outer supporting and brick ledge.

A further variant of the present design contemplates the provision ofend-to-end engaging components assembled at varied locations along anerected building wall and corresponding to a window or doorway opening.In such a variant, a plurality of “L” shaped members are typicallyemployed and which, upon being assembled together, define a structurewhich can be incorporated into such as an assembled brick and frameconstruction or poured wall construction.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference will now be made to the attached drawings, when read incombination with the following detailed description, wherein likereference numerals refer to like parts throughout the several views, andin which:

FIG. 1 is a first perspective illustration of an elongated “L” bond setupon a building foundation and according to a first preferred embodimentof the present invention;

FIG. 2 is an end cutaway of an “L” bond, such as referenced in FIG. 1,and further illustrating the features of an internal reinforcing insertincorporated within the “L” bond according to the present invention;

FIG. 3 is an end cutaway of a modified “T” bond according to a furtherpreferred embodiment of the present invention;

FIG. 4 is a perspective illustration of a pre-molded window or doorframe for incorporation into the building wall construction andaccording to the present invention;

FIG. 5 is a cutaway illustration taken alone line 5-5 of FIG. 4 andshowing the cross-sectional configuration of one of the bond elements ofFIG. 4;

FIG. 6A is a cutaway illustration of an “L” shaped bond elementaccording to a preferred variant of the present invention;

FIG. 6B is a cutaway illustration of a “T” shaped bond element accordingto a further preferred variant of the present invention;

FIGS. 6C-6E are cutaway illustrations of further modified “L” shapedbond elements according to the present invention;

FIG. 6F is a cutaway illustration of a bond cap according to the presentinvention;

FIG. 6G is a cutaway illustration of an exterior bond in use with thebond cap of FIG. 6F;

FIG. 7 is a perspective illustration of a modified bond and brick ledgesupport associated with a foundation support and according to thepresent invention; and

FIG. 8 is a cutaway illustration of a door and window framing memberutilized in combination with the bond according to the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIG. 1, a composite building component is illustratedat 10 according to a first preferred embodiment of the presentinvention. The component 10 is secured in extending fashion upon aconcrete foundation 12 and it is contemplated that the component mayeither be integrally formed with the foundation or, alternatively, canbe separately attached to the foundation through the use of heavy-dutyadhesives, fasteners, or the like.

In a first application, a plurality of the elongated components 10 areassembled in end-to-end fashion about the perimeter defining foundation10 and in order to define a lowermost bond layer associated with thefoundation. As discussed, the advantage of such a bond layer is that itprovides a degree of waterproofing, as well as termite and otherinfestation resistance, not found in other prior art applications and,most notably, in conventional wood bond constructions.

The elongated component 10 exhibits a substantially “L” shape with afirst foundation supporting ledge 14 and an interconnected and upwardlyextending ledge 16. In the application of FIG. 1, a plurality of floorjoists, illustrated in phantom at 18 and 20, extend in spaced-apartfashion between corresponding spaced apart and typically parallelcomponents (only one of which is shown at 10 in FIG. 1) and such thatthe ends of the joists are supported upon the components. As is known inthe art, such joist spacing can include indicia markings 22 and 24 whichcorrespond with conventional 16″ on center or 24″ on center applicationsin order to facilitate quickly aligning and assembling the floor joists18 and 20 in extending fashion between the opposing elongated bondcomponents 10.

The components 10 are typically constructed of a composite material inorder to exhibit the desired properties of strength and environmentalinsulation. Typically, the bond components are constructed, such aswithin a press operation utilizing a given forming temperature, as acomposite of a plasticized resin mixed with a sawdust and binder.Alternatively, the components may be constructed with fiberglass orother suitable material such that the finished product exhibits thenecessary properties of strength, durability, and environmentalinsulation.

Referring further to FIG. 2, a modification 26 of the elongated and “L”shaped component is shown and which includes a substantially resinousmaterial 28, within 5 which is encapsulated an interior reinforcingmember 30. The reinforcing insert may be embedded in axially extendingfashion within the elongated component, such as during its press orformation stage, and may include a metal, wood, heavy-duty nylon orother suitable material which provides the necessary degree ofreinforcement to the elongate extending component 26. The insert mayalso be configured to replicate the overall “L” shaped component 26,such as by exhibiting a likewise “L” shape in cross section, and inorder to maximize the overall rigidity of the component along its axialdirection. As will be further discussed, a reinforcing insert may alsobe provided in either a “T” shape or “U” shape configuration in order toprovide a likewise degree of axial rigidity to a correspondingcross-sectionally configured elongated component.

Referring now to FIG. 3, a further application of an elongated bondcomponent is illustrated at 32, again supported upon a buildingfoundation 12, and which is provided in a generally inverted “T” shapedconstruction. The elongated component 32, as illustrated by itscross-sectional cutaway, is constructed of a composite of a resinousmaterial and sawdust, and such as which is formed in a press with theselective application of heat and/or a binder element.

As with the “L” shaped embodiment of FIG. 1, the inverted “T” bondcomponent 32 of FIG. 3 may exhibit an inwardly facing floor joist ledge,see floor joists 34 and 36. Arranged on an opposite facing ledge surfaceis a brick ledge support such as which may support a plurality ofstacked bricks 38.

Referring now to FIGS. 4 and 5, a perspective illustration is shown at40 of a pre-molded window or door frame for incorporation into thebuilding wall construction. A plurality of elongated components 42, 44,46 and 48 are assembled in end-to-end fashion (such as againmechanically or through the use of adhesives) and such that they definean overall doorway or window frame. The variant illustrated defines aplurality of “L” shaped members and which, upon being assembledtogether, define a structure which can be incorporated into such as anassembled brick and frame construction or poured wall construction (notshown). As previously described, the interlocking elongate components42, 44, 46 and 48 for constructing a doorway/walkway are typicallycomposed of a material similar to that associated with the floor bondcomponents of FIGS. 1-3 and include a composite of a resinous/sawdust/binder or fiberglass material.

FIG. 6A illustrates at 50 a cutaway perspective illustration of an “L”shaped bond element, similar to that illustrated in FIG. 2, andincluding a reinforcing insert 52 according to a preferred variant ofthe present invention. FIG. 6B is a further succeeding cutawayillustration of a “T” shaped bond element 54 according to a furtherpreferred variant of the present invention, and which likewiseincorporates a likewise “T” shaped reinforcing component 56.

Referring further to FIGS. 6C-6E, successive cutaway illustrations offurther modified “L” shaped bond elements are shown at 58, 60 and 62,respectively, according to the present invention. In each instance, theconfiguration of the interconnecting ledges is modified, such as fordiffering floor and wall applications.

FIG. 6F illustrates at 64 a perspective cutaway of a “U” shaped bond capaccording to the present invention. The cap 64 may be assembledseparately upon a concrete foundation or may be used with an exteriorbond as further referenced at 66 in FIG. 6G. The exterior bond 66includes a modified “U” shaped cross-sectional configuration exhibitingan upper and rectangular shaped projection 68 upon which may be seatedthe cap 64.

As is further shown in FIG. 7, a modified foundation 70 is positionedintermediate an outer ground location 72 and an inner insulative layer74. The foundation 70 includes an upper square projection 76 which isdesigned to matingly engage within an opposing recess defined in axialfashion along a bottom-facing surface of the exterior bond 66. A brickledge support 80 (typically constructed of a metal or other suitablematerial) is configured to be secured upon the concrete foundation 70and includes an internally recessed projection 82, which matinglyengages over the cap engaging projection 76 in order to secure the brickledge 80 in place.

Finally, and referencing FIG. 8, a cross-sectional cutaway is shown of awindow or door framing member 84 which exhibits a modified rectangularshaped extrusion which includes a side-recessed and extending channel 86exhibiting inwardly recessed side walls and interconnected end wall. Themember 84 can be sectioned to any desired length and interconnected inend-to-end fashion to construct a door or window opening. In practice,an associated edge of an OSB board or the like (see at 88) can beinserted into the outwardly facing and extending notched recessedchannels 86 and nailed in place to establish a wall support surface. Themember 84 can be utilized in combination with the bond structuredescribed herein.

Having described my invention, other and additional preferredembodiments will become apparent to those skilled in the art to which itpertains, without deviating from the scope of the appended claims.

1. A composite building component for use with an erectable wallassociated with a building enclosure, the enclosure further including aperimeter-defining foundation, said component further comprising: anelongated body having a specified cross-sectional dimension, said bodybeing constructed of a composite including at least a plasticizedmaterial; and a plurality of said elongated bodies being secured inend-to-end connecting fashion upon the perimeter defining foundation,prior to assembly of additional building components associated with theerectable wall, and in order to provide an environmentally resistantbarrier proximate the foundation.
 2. The composite building component asdescribed in claim 1, further comprising a plurality of floor joistssupported in spaced apart and extending fashion between spaced apart andparallel extending components.
 3. The composite building component asdescribed in claim 1, said elongated body having a specified shape andsize and further comprising a combined composite of plasticized resinand sawdust.
 4. The composite building component as described in claim1, said elongated body having a specified shape and size and furthercomprising a fiberglass composition.
 5. The composite building componentas described in claim 1, said elongated body having a specified shapeand size and further comprising an axially extending and internalreinforcing insert.
 6. The composite building component as described inclaim 5, said reinforcing insert being constructed of a materialincluding at least one of a metal, wood, and nylon.
 7. The compositebuilding component as described in claim 1, said body having a specifiedshape and size and exhibiting an “L” shaped cross-sectional dimension.8. The composite building component as described in claim 1, said bodyhaving a specified shape and size and exhibiting a “T” shapedcross-sectional dimension.
 9. The composite building component asdescribed in claim 1, said body having a specified shape and size andexhibiting an inverted “U” shape in construction.
 10. The compositebuilding component as described in claim 1, further comprising anelongated brick ledge attachment disposed between the foundation and theinterconnecting composite bodies.
 11. The composite building componentas described in claim 1, further comprising a plurality ofinterconnected bodies, each exhibiting an outwardly facing and recessedchannel, a panel edge seating within each of said panels and beingsecured in place.
 12. A plurality of composite building components foruse with an erectable wall associated with a building enclosure, saidcomponents each further comprising: an elongated body having a specifiedcross-sectional dimension, said bodies being constructed of a compositeincluding at least a plasticized material; and a plurality of saidelongated bodies being secured in an end-to-end and perimeter-definingfashion, in association with the erectable wall, in order to provide anenvironmentally resistant barrier.
 13. The composite building componentas described in claim 12, each of said elongated and perimeter-definingbodies further comprising an “L” shaped cross-sectional dimension. 14.The composite building component as described in claim 12, saidelongated and perimeter-defining bodies having a specified shape andsize and corresponding in arrangement and placement to at least one of awindow and doorway.
 15. The composite building component as described inclaim 12, said bodies each having a specified shape and size and furthercomprising a combined composite of plasticized resin and sawdust. 16.The composite building component as described in claim 12, saidelongated bodies having a specified shape and size and furthercomprising a fiberglass composition.
 17. The composite buildingcomponent as described in claim 12, said elongated bodies each having aspecified shape and size and further comprising an axially extending andinternal reinforcing insert.
 18. The composite building component asdescribed in claim 17, said reinforcing insert being constructed of amaterial including at least one of a metal, wood, and nylon.
 19. Aplurality of composite building components for use with an erectablewall associated with a building enclosure and for establishing a floorsupporting bond, the enclosure further including a perimeter-definingand concrete foundation, said components each further comprising: anelongated body having a specified cross-sectional dimension, said bodybeing constructed of a composite including at least a plasticizedmaterial, said elongated bodies being secured in end-to-end connectingfashion upon the perimeter-defining foundation; and a plurality of floorjoists supported in spaced apart and extending fashion between spacedapart and parallel extending components comprising saidperimeter-defining foundation, said components establishing anenvironmentally resistant barrier proximate the foundation.
 20. Thecomposite building component as described in claim 19, said elongatedcomponents each exhibiting a specified shape and size and furthercomprising a brick ledge support location in addition to a floor jointsupport location.
 21. The composite building component as described inclaim 19, each of said bodies having a specified shape and size andfurther comprising at least one of an “L” shaped, “T” shaped and “U”shaped cross-sectional dimension.